Exterior polymer-based brick building material

Abstract

A simulated brick includes a polymeric core member, a mesh layer adhered to the core member, a basecoat layer covering an entirety of the mesh layer, and a finish layer covering an entirety of the basecoat layer. The core member, the mesh layer, the basecoat layer, and the finish layer together define a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion.

The invention claimed is: 
     
       1. A simulated brick comprising:
 a polymeric core member; and 
 a laminate comprising a mesh layer adhered to the core member; a basecoat layer covering an entirety of the mesh layer; and a finish layer covering an entirety of the basecoat layer; 
 wherein the core member and the laminate together define a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion; 
 wherein the laminate covers the core member to define the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member is uncovered by the laminate on the base surface such that the core member defines the base surface. 
 
     
     
       2. The simulated brick of  claim 1 , wherein the second thickness is between 5% and 70% of the first thickness. 
     
     
       3. The simulated brick of  claim 1 , wherein the second thickness is between 35% and 60% of the first thickness. 
     
     
       4. The simulated brick of  claim 1 , wherein the brick profile portion has an R-value of at least 2.0 h·° F.·ft 2 ·in/BTU. 
     
     
       5. The simulated brick of  claim 1 , wherein the offset portion has an R-value of at least 1.0 h·° F.·ft 2 ·in/BTU. 
     
     
       6. The simulated brick of  claim 1 , wherein the mesh layer, the basecoat layer, and the finish layer together form a laminate having a thickness of approximately ⅛ inch. 
     
     
       7. The simulated brick of  claim 1 , wherein the core member comprises at least one of polystyrene, extruded polystyrene, expanded polystyrene, polyisocyanurate, polyurethane, and foam glass. 
     
     
       8. The simulated brick of  claim 1 , wherein the mesh layer comprises at least one of fiberglass, polyester, polypropylene, aramid, and carbon. 
     
     
       9. The simulated brick of  claim 1 , wherein the mesh layer comprises a fire resistant material. 
     
     
       10. The simulated brick of  claim 1 , wherein the finish layer comprises at least one of acrylic, vinyl acrylic acetate, veova, and styrene acrylic. 
     
     
       11. The simulated brick of  claim 1 , wherein the core member has a density between about 0.5 pcf and about 5 pcf. 
     
     
       12. The simulated brick of  claim 1 , wherein the basecoat layer comprises polymer-modified cement. 
     
     
       13. The simulated brick of  claim 1 , wherein the brick profile portion and the offset portion extend longitudinally between first and second longitudinal end surfaces, with the core member being uncovered by the laminate on the first and second longitudinal end surfaces such that the core member defines the first and second longitudinal end surfaces. 
     
     
       14. The simulated brick of  claim 1 , wherein a junction between the outer surface of the offset portion and the first lateral surface of the brick profile portion comprises a radius surface. 
     
     
       15. The simulated brick of  claim 1 , wherein the second lateral side of the brick profile portion comprises a planar surface extending from the base surface to the outer surface of the brick profile portion. 
     
     
       16. The simulated brick of  claim 1 , wherein the lateral end surface of the offset portion comprises a planar surface extending from the base surface to the outer surface of the offset portion. 
     
     
       17. The simulated brick of  claim 1 , wherein:
 the brick profile portion and the offset portion extend longitudinally between first and second longitudinal end surfaces, with the core member being uncovered by the laminate on the first and second longitudinal end surfaces such that the core member defines the first and second longitudinal end surfaces; 
 the second lateral side of the brick profile portion comprises a planar surface extending from the base surface to the outer surface of the brick profile portion; and 
 the lateral end surface of the offset portion comprises a planar surface extending from the base surface to the outer surface of the offset portion. 
 
     
     
       18. The simulated brick of  claim 1 , wherein the second lateral side of the brick profile portion comprises a planar surface extending perpendicularly from the base surface to the outer surface of the brick profile portion. 
     
     
       19. The simulated brick of  claim 1 , wherein the lateral end surface of the offset portion comprises a planar surface extending perpendicularly from the base surface to the outer surface of the offset portion. 
     
     
       20. The simulated brick of  claim 1 , wherein:
 the brick profile portion and the offset portion extend longitudinally between first and second longitudinal end surfaces, with the core member being uncovered by the laminate on the first and second longitudinal end surfaces such that the core member defines the first and second longitudinal end surfaces; 
 the second lateral side of the brick profile portion comprises a planar surface extending perpendicularly from the base surface to the outer surface of the brick profile portion; and 
 the lateral end surface of the offset portion comprises a planar surface extending perpendicularly from the base surface to the outer surface of the offset portion. 
 
     
     
       21. A simulated brick comprising:
 a polymeric core member; 
 a mesh layer adhered to the core member; 
 a basecoat layer covering an entirety of the mesh layer; and 
 a finish layer covering an entirety of the basecoat layer; 
 wherein the core member, the mesh layer, the basecoat layer, and the finish layer together define a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion; 
 wherein the finish layer defines the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member defines the base surface. 
 
     
     
       22. A method of manufacturing a simulated brick, the method comprising:
 forming a polymeric core member including a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion; 
 adhering a mesh layer to the first and second lateral sides and the outer surface of the brick profile portion and to the lateral end surface and the outer surface of the offset portion; 
 depositing a basecoat layer onto an entirety of the mesh layer; and 
 depositing a finish layer onto an entirety of the basecoat layer; 
 wherein the mesh layer, the basecoat layer, and the finish layer together form a laminate that covers the core member to define the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member is uncovered by the laminate on the base surface such that the core member defines the base surface. 
 
     
     
       23. The method of  claim 22 , wherein forming the polymeric core member comprises wire cutting an insulation board to form the brick profile portion and the offset portion. 
     
     
       24. The method of  claim 22 , wherein adhering the mesh layer comprises applying a self-adhesive surface of the mesh layer to the first and second lateral sides and the outer surface of the brick profile portion and to the lateral end surface and the outer surface of the offset portion. 
     
     
       25. The method of  claim 22 , wherein depositing the basecoat layer onto the entirety of the mesh layer comprises extruding the basecoat layer onto the entirety of the mesh layer. 
     
     
       26. The method of  claim 22 , wherein depositing the finish layer onto the entirety of the basecoat layer comprises extruding the finish layer onto the entirety of the basecoat layer. 
     
     
       27. A wall system comprising:
 a wall substrate including a substantially planar exterior surface; and 
 at least first and second simulated bricks, each comprising a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion, each of the first and second simulated bricks comprising a polymeric core member and a laminate comprising a mesh layer adhered to the core member; a basecoat layer covering an entirety of the mesh layer; and a finish layer covering an entirety of the basecoat layer, wherein the laminate covers the core member to define the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member is uncovered by the laminate on the base surface such that the core member defines the base surface; 
 wherein the planar rectangular base surfaces of the first and second simulated bricks are adhered to the exterior surface of the wall substrate such that at least a portion of the lateral end surface of the offset portion of the second simulated brick abuts the second lateral side of the brick profile portion of the first simulated brick; and 
 wherein a grout material is adhered to the outer surface of the offset portion of the second simulated brick. 
 
     
     
       28. The system of  claim 26 , wherein the first and second simulated bricks are substantially identical. 
     
     
       29. The system of  claim 27 , wherein the adhesive layer comprises at least one of polyurethane foam, polyurethane construction adhesive, and acrylic based adhesive. 
     
     
       30. The system of  claim 27 , wherein the grout material comprises at least one of Type N cement mortar, Type S cement mortal, and elastomeric sealant.